Process of making orthopedic braces



Nov. 29, 1949 R. ANDERSON PROCESS OF MAKING ORTHOPEDIC BRACES 4 Sheets-Sheet l Filed April 11, 1944 m am w. me R Nd o wn .n mA MA I NOV. 29, 1949 R ANDERSON PROCESS OF MAKING ORTHOPEDIC BRACES 4 Sheets-Sheet 2 Filed April 11, 1944- ZQQLIDJOW UZOPNQ( m0 agar Hna/arson BY M muy AT ToRNaYs Nov. 29, 1949 R, ANDERSON 2,489,252

PROCESS OF MAKING ORTHOPEDIC BRACES 4 Sheets-She'et 5 Filed April l1, 1944 BY www@ ATToNEYs NOV' 29, 1949 R. ANDERSON PROCESS OF MAKING ORTHOPEDC BRACES 4 Sheets-Sheet 4 Filed April l1, `1944 Patented Nov. 29K, 1949 UNITED STATES `PATENT OFFICE PROCESS F MAKING ORTHOPEDIC BRACES Roger Anderson, Seattle, Wash. Application April 11, 1944, Serial No. 530,472 7 Claims. (Cl. `12S-90) My invention relates to a process of making an orthopedic brace from a plastic.

Referring more particularly to orthopedic casts and splints, the heretofore most generally employed method for securing immobilization and supporting certain parts of the human body employs plaster of Paris casts. This method generally comprises dipping prepared bandages made of plaster coated strips of cotton fabric into water, disposing the so-moistened plaster bandages in the desired position adjacent the desired part of the body, and allowing the plaster of Paris to set and dry so it will assume its function as a rigid supporting means.

`While the conventional plaster of Paris cast is `useful in providing valuable therapeutic results, it has many and recognized shortcomings. For example, the cast is characterized by excessive weight, its setting period to obtain maximum strength is long, it remains damp for long periods and thus often provides adverse conditions from a therapeutic standpoint, it is dense, and to a greater degree when wet, to electrical rays, and it is highly absorbent to liquids including body secretions, water and air-borne moisture. The absorbent characteristics of the plaster cast are not only favorable for germ in'- cubation but the strength of the cast is progressively lost depending upon the amount of secretions, water and moisture to which the cast is4 exposed. These disadvantages and others have provided a long felt need in the art to provide an entirely new type of cast or splint.

In view of this need in the art, I have devoted much of my attention for many years past in research to provide a new type of cast or splint formed from a plastic. In my co-pending applications No. 469,843 and No. 449,890 (now Patents 2,384,804 and 2,373,802) and in my issued Patent No. 2,308,483, I have disclosed and described a new type of plastic cast. A feature of the inventions of said applications and said pat-r ent relates to the providing of a multiplicity of discrete pieces of a plastic about or adjacent an injured member and with the pieces contacting to provide a multiplicity of contacting portions. Such inventions function by employing a solvent means for securing the pieces together at their contacting portions. I disclosed that where the discrete pieces were formed of a material as cellulose-acetate that a solvent, as acetone, could be employed. The action of the acetone included the providing of a relatively thin dissolved film on the peripheries of the discrete pieces which upon setting would secure the pieces together at their contacting portions. This limited dissolving of the pieces only on their surface portions was obtained by the physical characteristics of the pieces and thus I was able to provide a quick setting cast and one of substantial strength.

It is a characteristic of plastics that if a substantial amount of the same is dissolved and then characterized by forming an air-excluding sur--` face lm so that we have surface hardening or `surface film and with very slow internal drying or setting. Thus, such a dissolved plastic :in gelata predetermined limited or small amount of plasv tic may be dissolved and the great bulk of the inous form in and of itself is not practical, in accordance with my invention, to provide a cast. In View of the provision of discrete pieces in my inventions in said applications and said patent,` I was able to mechanically limit the dissolving of the pieces.

It is further the object of the invention to form a waterproof, relatively rigid, unyielding and in-,1 p elastic cast or splint which will possess a maxi-v4 mum strength combined with a minimum weight.

It is an object of the present invention to provide a plastic fabrication which is very similar to the touch and in appearance to knitted yarn, Aas sweater material or stockinette and preferably provide the same in the form of a tubing or a form iitting member or in strips of suitable width and thickness so that such material may 4 be properly fitted or wrapped about or adjacent an injured member and may be thereafter setup to form a cast or splint. One distinguishing feature of my present invention over my inventions in the beforementioned applications andV letters patent, is that in my present invention my starting material is of a character, such as Y, 5 brous or lament character, so that if prior, art methods were followed, it would interact with normal plastic solvents and gelatinize. In the present invention I control the physical-chemi- 4 cal conditions to limit and/or eliminate the nori mally expected substantial gelatinizing reaction y between a brous material and a solvent for such fibrous material.

It is a further object of my invention to provide a cast member characterized in a substantial -maintaining of the structural form of the starting material so that the cross sectional characteristics of the cast material, when said materialis applied, will be substantially retained in the` completed cast to form a truss-like structure in lthe completed cast. It is a further object of the invention to prop vide a bandage-like material of a plastic origin' which may be applied without the need of any. greater skill than is necessary to apply an ordinary bandage about an injured member.

It is the furtherobject of the invention to provide a treating solution having a predeter-` mined limited or maximum capacity for dissolving v` portions of the plastic material employed so that vide a cast which not only rapidly sets but which 3 rapidly dries and one in which the major strength and the dry state of the cast are substantially attained in a matter of minutes-thus providing in a short periodfor substantial strength and a't the same time with the elimination of moisture conditions. The presence of moisture for long periods of time may be conducive to complications such as pneumonia. 'lsothe 'provision of substantial strength to a cast in a shortfperiod of time is often invaluable for therapeuticreasons and to permit a minimum -anaestheticpericd It is another object of the invention `to provide a prepared cast-forming material whichis flexible, pliable and particularly adapted for conformation in form ttingrelaton-about parts ofthe human body, a treating solution therefor which may be applied --with great vlatitude o f technique and still withcertainty of results, and a process for employingthe same which is characterized by its ease or simplicity of application so-that a perfect t ofthe cast'may be attained ev'en by less adept physicians and surgeons and with maximum latitude of technic.

`It is a further object-of Athe invention toprovide a cast which may bereadilycut or severed, mechanically, chemically or both mechanically and chemically, for removal, extension, joining, local adjustment, or rei'ltting, Vand la cast which after severance (or which may require repair for any other reason) may be readily repaired or reenforced without'loss ofy'but usually with, increased structural strength.

It is a further object ofthe invention to provide a vcast-forming material or fabrication in which shrinkage characteristics may be predetermined oreliminated so that in turnfthe shrinkage during setting of the final cast vmay be likewise predetermined or eliminated so there result a proper t or conformation of the cast to the adjacentor encased body/portion, and a desirable unity or coherence in'thelayers of the cast.

"It is a further object of the invention to provide-a process for pretreating the cast-forming material Vso that there yresult 'control and/or eliminationof the shrinkage'which would otherwise be brought about upon application of the treating solution to the material.

It is a further object of the invention to provide a practical plastic cast which'will 'be unaffected by moisture, as body secretions, water or "air-borne moisture, transparent to electrical rays, such as X-rays, or ultra-violet" treating rays, and which may be of an open mesh structureso that the cast will facilitate treatments, such as of the cast or the injured member l'by liquids of various natures.

It is a further object of the'invention to provide an open weave mesh'fabrc as the starting material wherein by the fibrous or filament character and open weave thereof, "the wetting characteristics of the material are enhanced. `Because of the use of limited dissolving properties. 'I am able to use an exceedingly open weave fabric without damage to such fabric, a fabric having exceptional wetting properties, and a fabric havingthe desired thickness and a minimum weight-thus providing a completed cast of minimum weight and Imaximum strength.

It iS a further obiectofthe invention to provide a cast-forming material preferably having inert threads therein which will aid in control of the shrinkage characteristics during forming my completed cast.

'It is a further object of the invention to provide my treating solution having.

4 a method of applying the treating solution to provide for economy in use of the treating solution, uniformity of wetting of the cast-forming material bythe treating liquidfsolution, and utmost convenience to the operator in that suincient solution treated cast-forming material in a c'losable receptacle will be readily available.

v'-Ihe-above mentioned general objects of my invention, together With others inherent in the same, are attained by and illustrated in the structures lillustrated in the following drawings, the same being preferred exemplary forms of embodiment of my invention, throughout which drawings like reference numerals indicate like parts:

Figure 1 is a fragmentary and somewhat schematic view illustratio'na fabrication, before'trea'tment, employed in the invention;

Fig. 21isfa view ofthe fabrication of Fig. l1 after pretreatment in accordance withvmyinvention';

Fig. 3isa View of the fabrication of Fig. 1k affter final treatment;

Fig. 4 isa View similar to'Fig. l of a modified formof fabrication employing therein, in addition tothe plasticpan'inert-thread or yarn;

Fig. 5 is a View of thelfabrication of Fig. 4fafte'r nal'treatment;

Fig. 6 is 'a fragmentary lview with portions shown -in section `and portions ineleva-tion of a cast offmy inventionapplied about avportiono'! the human body;

Fig."7 isan enlarged'fragmentary View of par-ts shownin section in'FigG;

Fig. Svisva viewsimilar to Fig. fexcept that-the outer layer of the-ca'stisfprovided by a tubular member instead of abandage;

Fig. 9 is a sectional view'taken substantially on broken line'9-9-of Fig.'8;

yFig.10l is a fragmentary -view and withportions shown in eleva-tion' and portionsfshown in' section to'illustrate the useof-padding means betwee'nfa sore'spot or bony prominence, as an elbowyand a castor-my invention;

Fig. 111 ris a fragmentary view vwith portions shownin elevationI and portions shown in section to'illustrate a means of applying a solvent to remove portions,as a lregular o-r irregular-shaped hole,Y of av completed cast of my invention; n

"Fig =1-2 is a fragmentary View with portions shownv infelevation and portionsshown in section offa completed cast of `my invention in which an openinghasbeen provided and the cast then repaired;

Fig. 13 is a viewsimilartoFig. 1'1 'except that the nature of the opening to be. provided in the cast'isalong narrovv'slotsuch as may be employed in severing and removing the cast;

Fig. 14 isa viewivvithfparts shown in section and-partsshown in elevation of a device which maybeemployedfin applying treating solution-'of my invention tothe fabrication of my invention;

Fig. 15 isa chart comparing the saturation values-of a treating solution employed in my invention with thepercentage-of acetone employed v-in the said solution;

Fig. 16 is a, longitudinal sectional view, with parts shown in elevation, and with parts shown somewhat diagrammatically, of a device employing a fabrication pretreatment method of my invention; and

Fig. v17 is a viewsimilarto Fig. -16 showing a device illustrating a modified fabrication pretreatment method.

Plastic employed characteristics: It is soluble in the treating solution employed (the relative extent being considered under the title Treating solution), it is relatively inelastic, and it is capable of being formed into pieces of threadlike dimension in section and preferably as a fiber or threadlike filament so that a yarn or thread may be provided from the same. Typical examples of such plastics are:

A. The cellulosic plastics {An-CHT] C. Vinyl ester plastics 1. Polyvinyl acetate GHz-Cliff 1 OOCHB n 2. Polyvinyl chloride CH2- CH- l l., 3. Polyvinyl chloride acetate -CHIFCH-CHZ-CH-ong-CH- l a I CH-O- oooCH CL 4. Copolymers of vinyl acetate and vinyl chloride l v(The above chemical formulas are the conventional representatons of theplastics involved. However, commercial furnished plastics are not completely esterined as might be indi-cated by the chemical formulas.)

Form of materials The various individual fibers or filaments of the plastics mentioned in the foregoing paragraph are preferably woven into yarns, suoli as standard yarns of 150 denier weight. It is to be understood that the foregoing gure of 150 denier weight is not a limitation of this invention but is merely an example of a yarn which may be employed and which is at the same time a standard yarn. Pref- V erably more than one piece of yarn is employed and asa practical example I have employed twelve individual pieces of yarn, each of 150 denier weight, and employed them as a unit in the knitting process.

From the knitting process I preferably obtain, for cast forming purposes, a stretchable and relatively thick fabrication. Thus the type of stitch to be employed in the knitting machine preferably should be one which provides a relatively stretchable fabrication and at the same time the tension on the threads preferably should be relal tively loose. As typical examples of various types 6., ting of the fabrication employed in my invention, I have used the following stitches: cuff, link and link, full cardigan, full cardigan with rack, tubular and stockinette.

While the yarn employed in making the material into a stret'chable and relatively thick knitted. fabrication may be solely a plastic, I prefer to employ an inert material in each unit of yarn employed in the knitting process to control shrinkage. This material will be inert to the treating solution employed (treating solutions are hereinafter specifically considered) and if the treating solution employs therein acetone then the inert material (that is inert so far as acetone is concerned) may be cotton, regenerated rayon,

glass, metal, Nylon, etc. An example of an inert thread employed in the fabrication of my invention is shown in Figs. 4 and 5 of the drawings. In such gures a plurality of plastic threads or yarns are disposed alongside and adjacent inert threads, as an inert thread I0. In the event that an inert thread is employed, it will control adverse shrinkage in the ultimate overall size of the cast.

A theoretical explanation of the operation of the inert thread means is illustrated in Figs. 4 and 5. Fig. 4 illustrates a fragment of the fabrication 26 before treatment and Fig. 5 illustrates the same after treatment. Thus the thickness of the fabrication, as dimension I2 of Fig. 5, appears to be reduced below thickness I3 of Fig. @l blut the length I4 of both figures (a length or Width dimension of the nal cast) remains substantially constant. The inert thread means, by providing the thick material of Fig. 4 with excess material therein, permits the material to reduce its thickness and preserves the length dimension at right angles thereto.

Fig. 1 illustrates the fabrication 26 before treatment. Fig. 2 illustrates the same after pretreatment in accordance with the technic discussed under Technic or method of invention, apparatus employing method of pretreating cast-forming materia, described hereinafter, and Fig. 3 illustrates the same after final treatment. The threads or yarn of the fabrication as woven (Fig. 1) appear thicker in section and have more nap" or fuzz After pretreating as shown in Fig. 2, the loops have an apparent greater width as dimension l5 of Fig. 2 compared to dimension I6 of Fig. 1. Then after final treatment to provide a rigid supporting means as a cast the dimension I1 of Fig. 3 is reduced over the comparable dimension I5 of Fig. 2. However, the dimension I8 of both Figs. 2 and 3 is substantially constant so the shrinkage of a cast tending to reduce its size is substantially eliminated.

The fabrication is preferably provided in strips which may be of various Widths. The exact Width of the material will be determined by the type of Varticle which is to be made. In other words, the

narrower the strip the easier it will be to conform the strip about an irregular shaped object and at the same time the wider the strip the faster the material may be applied. Thus for practical .purposes I have employed strips varying in width from two to ten inches and a length for convenient handling.

Another form of fabrication which I have employed in my invention is knitted tubing or ma- .1 terial knitted substantially to the shape of a particular member, as a trunk, leg, etc., such as a stocking.

`Other forms of fabrications will include woven material, matted material, intertwined material 4or intermeshed material. The means for holding of stitches which have been employed in the knt- 76 the fabrication together so the same may be handledasa unit-may be the-crossfthreadsofa weave or knit, -the entangled threads of fmatted, intertwined or intermeshed material, `or mechanical means as weld-like means, adhesive means, sewing, vporousflexible containers, or the like. The requisitecharacteristic of fthe vfabrication lis that it rmust comprise a plurality-of pieces whereinrthe plasticemployed is-of lament or rthreadli'ke'vdimension in-section and the-'pieces :are interconnected to provide a unit or fabrication. .The structures of my earlier mentioned patent and patent applications have a dimension in `section oi v-more than one thirty-second of an inch. In such instances the size and dimension of Vthe plastic permitted the useof normal solvents, .as acetone, without excess dissolving. In thefpresent invention I employ plastics having a dimension of less thanone thirty-second of an'inch and'which maybe termed of threadlike dimensionlin section. Becauseof their dimension they `would be 'dissolved, lose shape, take too long to dryzor'setfor adverseamounts of gelatinous matter would be formed if normal solvents, as distinguished from treating solutions having the limited solubility characteristics herein dened, were employed. Thus the structures or Afabrications within the scope of this invention Iwill also include (so long as the cross section of plastic employed is within the present teachings andregardless-of whether a solid member of plastic, a hollow ymembertof plastic, or a member coated with a `.plastic employed) threads--long `or short, .tubeslong or short, and other geometric solids, as beadsfflai..l

solids, etc. In the event that 4pieces of :short length'are employed they may befabricated'to be handled asa unit'by employing them -withina porous flexible container as a bag. Alsmat solids may-be secured together, much like :shingles for sh scales, merely at one end. .'Also, if an inert thread vis selectively coated at longitudinally spaced locations, the ilexibility of the funcoated portions-may beiutilized. In thedescriptionsand in the claims the word fabrication is soused and shalll have'such meaning unless the context .re-

quires a I different meaning.

fPre'treat'ing of the cast-forming Amaterial Preferably-the fabrication previouslydescribed is. pretreated before application about .an injured member so that the subsequent .shrinkage char tion of the pretreating technic-will be'foundin' connection `with `the detailed description Vof Figs. 16and 17 and will no-t be zhere'repeated. :However, atxthis point Ifdesire to pointout'that in the technic of applying casts,controllof .the/subsequent shrinkage during setting `of vthe'cast 'is highly desir-able. In `many cases it is-desirabl'e thattherefsh'all be lno shrinkage Vof the cast `and in other I cases variations 'in the r degree o'f shrinkage are desirable fortheutmost therapeutic results'depending upon the nature of the injury involved and/ or the nature of the treatment Idesired. yFor example, acastmay'beapplied about a recently amputated stump where the conditions are such that the surgeon'desires-pressure to reduce the swelling. Infsuch cases the shrinkage during setting may be had so that pressure is applied to the swollen area. Also in such a type of case,.a castwill have'an'increasingly greater iit-'orfconformation upon the gradual decrease-of the swelling. Afi'urther i advantage tfrom" applying". m-y `cast in such :acase lis `that'a temporary .artis ficial limb-maybe readily secured to thefcast and? the patient :will i'be promptlyambul'a'tory. Alsolaf cast may fbefapplied .aboutan injured 'limb shortly' after the .fracture and before c'onsiderablecswell-vv ing has set in and Aintsuch cases .a minimum .'of shrinkage "of `.the cast vin .the setting-up process may be desired to allow for the anticipatedfsub-.l lsequent swelling. Also a cast .may be .applied about very bony prominences and where minimum swelling may be expected.

The technic of the useA-offcasts varies with the individual case and the operator and it is not my intention to indicate a methcd'of treatment but merely to indicate some Yexamples showing possible uses of controlling the shrinkage characteristics of the cast duringfsetting.

Treating solution A prime consideration in my invention is that the treating solution shall Vbe `of a character to become saturated at 4a very low concentration with the plastic employed and/or'have the capacity below a predetermined maximum to react with the plastic employed. Such treating solution may be a solvent for theplas'tic employed, such as ethyl-acetate; a-solvent vvforsucln plasticA combined with a diluent, `as acetone and pe"' `troleum ether; two -or more non-solvents for such plastic whichiin combination `act as a solvent, as chloroform and ethyl alcohol; or .any .0L the foregoing which have been rst saturated'byl such plastic.

In the event that my :invention is to be employed in connectionivvith the medical and surgical elds in providing casts or splints `then the treating solution should'be relatively volatile to provide for rapid settingfofthe cast or splint and .rapid drying of solution, should not be harmful or irritating to theskin or exposed flesh-or sores, if any, should notbe toxic, andshould not have an undesirable odor.

In order to determine the amount of a particular plastic requiredfto saturate agparticular treating solution (hereinafter termedsaturation value of a treating solution), I employed one hundred cc. of the solution being'tested and placed therein in nely comminuted forman excess oftheplastic to be'employed in connection with the particu- "lar treating solution land allowed the "same Atov stand in a closed Wessel for a substantial period of time to insure complete vsaturation of the treating solution by the plastic. Whilethetreating solution and theplastic would only .be in as- A.- `-soci-ation with one another for a matter of minutes in actual use in my invention, nevertheless,. for test .purposes I ipermitted -zthe treating sol-u tion and the plastic to stand in a vclosed vessel for twenty-four hours to obtain results capablef,r "of being duplicated vas to saturation values. y1111.-...- view of the fact that an excess of plastic was employed to insure that the solubility characteristics of the treating solution would be-fully satisfied some undissolved plastic and. usually some. "gelatinous material were present. Then .the lift-"f uid was passed through a filter paper sorthattonlv dissolved plastic would be present in the liquid i filtrate. Thereafter a Vmeasured,amount of liq- .J uid ltrate ywas evaporated -to dryness `and the residue weighed.

With vsuch technic for determining the tion values .of treatingsolutions formedrof'vari* f. ous ingredients and a .specic example -of reach; ...combination (and to .compare thesametopthe),

saturation value of pure acetone-with acetone less than enough plastic to leave undissolved pieces was employed so filtering was not needed) in connection with a typical commercial cellulose acetate yarn (at a room temperature of about 70 F.) the following results were observed:

C n lil/gillgramstof omposi on ce u ose ace ate Treatmg Solution (by volume) per 100 cc. treat` lng solution Per cent Acetone 100 over 100,000.0

Acetone 68 35. 0 Petroleum ether (3560 C.) 32

Acetone 56 Toluene 44 76.0

Methyl acetate 68 Petroleum ether (3560 C.) 32 32. 5

Methyl acetate 60 Ethyl other 40 34. 5

Methyl formate 70 Petroleum ether (35-60 C.) 30 26.3

lIYIethlyl formtte .g 60

etro eum e er 37 Methanol, ma; 40 18 3 Methyl formate 66 Ethyl ether 34 71.3

Chloroform 99% Ethyl alcohol 61 49. 5

The striking contrast of the low saturation Vvalues of the various treating solutions, set forth the invention is not limited to the saturation values set forth in said table by way of example and the limits of the invention will be hereinafter defined.

Also, in the table it will be apparent to those skilled in the art that examples of a solvent and a diluent therefor are involved in some of the treating solutions. For example, acetone is a solvent for cellulose acetate, and petroleum ether is a diluent for acetone. and the diluent obviously do not function in direct relation to the amount thereof present, as the treating solution containing approximately two-thirds acetone and one-third petroleum ether (by volume) has a saturation value of 35 milligrams rather than two-thirds of one hundred thousand milligrams.

Referring to the graph, Fig. 15 of the drawings, the ordinates represent milligrams per 100 cc. of

However, the acetone 10 comprising acetone and petroleum ether is believed obvious in view of said chart.

In View of the fact that those skilled in this art can readily prepare a saturation chart for any of the treating solutions which I have disclosed, I have deemed it unnecessary to here set forth a chart for each treating solution. However, after a saturation chart is obtained for the treating solution embodying the technic which I have hereinbefore disclosed, then a treating solution having the proper saturation value may be readily obtained for a given plastic and employed in my invention. Many of the saturation charts for the treating solutions which I have disclosed will follow generally the curve disclosed in Fig. 15. However, many of the treating solutions of this invention will have saturation value curves which are very dissimilar to the curve represented in Fig. 15. In connection with a treating solution comprising chloroform and ethyl alcohol, I may employ a solution wherein a very small amount of chloroform is present and a very large amount of ethyl alcohol is present, and at the same time treating solution. The abscissas represent the-- percentage of acetone in a treating solution comprising acetone and petroleum ether. From said chart it will appear that in order to obtain treating solutions having a saturation value of less than 300 milligrams per 100 cc. of treating,

sired value of saturation for a treating solution I may employ a treating solution wherein. a large amount of chloroform and a very small amount of ethyl alcohol are present.

Another type of treating solution which may be employed in the invention includes solutions which have been previously treated with the plastic involved. For example any of the solutions mentioned in the said table may be treated by and even up to saturation by the plastic to be employed and even after substantially complete saturation they are operable in my invention as treating solutions.

Other types of treating solutions described in said table will include a solvent as ethyl acetate or a combination of non-solvents in and of themselves which function in combination as a solvent as chloroform and ethyl alcohol,

A possible theoretical explanation which may be involved in the action of my treating solutions is that one liquid as ethyl alcohol may function as a disperser and another as chloroform may function as a swelling agent. Thus the chloroform may function to swell the plastic so portions will sluf olf and/or be made available to be acted upon by the disperser. One of the facts which can be explained by this theory is that solutions containing a large amount of chloroform and a small amount of ethyl alcohol give limited solubility characteristics and at the same time solutions containing a small amount of chloroform and a large amount of ethyl alcohol give similar results. Thus by either controlling the swelling action or by controlling the dispersing action, limited solubility may be obtained. The action to which I have referred as a swelling action may be appropriately referred to as merely a stage of or an action occurring in dissolving. As to treating solutions containing agents, as acetone, it appears that the swelling action, if present, and the dissolving action are brought about by the same agent, acetone, which seems to give credence to the theory that swelling is a stage of dissolving. However, despite the theory involved, my experiments have demonstrated the utility of treating solutions having low saturation values.

Thus my investigation indicates that it is necessary to employ a treating solution having a low saturation value for the plastic employed and/or a treating solution having a capacity below a predetermined maximum to react with the plastic employed and thus provide the necessary settion, there isa destruction of the fabrication and .its structural form to lan adverse degree, and for- .mation of .an adverse amount of .gelatinous materia'l--these result .in .prolonged setting and 'dry- `ing time and a thin and weakened cast.

While .I am unable at this time to positively state the theoretical reasons for the phenomenon as to Why .treating solutions having .low saturaltion values are .operable .in my invention, one lpossible explanation `is that their capacity to d1ssolve plastic Ais satised before the occurrence .of

any lsubstantial destruction of the structure .of the Afabrication and that the dissolved .plast1c` lis so dispersed or `distributed that substantial Aquantities of a `gelatinous mass are not .formed- Also the lprefere'baly employed highly volatile 'treating solutions limit the time for the interaction between the `treating solution and the plas- 'tic so that where .said preferable solutions .are employed a minimum dissolving .of the .plastic takes place. Also, a possible feature which may 'be involved in the theoretical .explanation `is that.

there 'is a capillary attraction between the various hair-like iibers or `lila-ments making up the various pieces of yarn or thread or fabrication vkand the treating solution, so that in the time involved 'in the reaction period, 'the Ymajor action is :between the treating solution which `first iwetted'the plastic and the plastic itself, and the excess or subsequent applications of treating solution do not bringabout excessive dissolving of 'the plastic.

A possible theoretical .reason as to `Why substantially vsaturated or partially saturated solutions Will be voperable in the invention is that of migra-tion 'or exchange. Even though the treating solution is 'substantially saturated with the plastic involved, it appears that there is an expelling of thelplas'tic which saturated the solution and va simultaneous `dissolving ofthe plastic "to be Itreated so that by migration or exchange K 4that the `saturation value yfor saturation value for treating solutions of treating solution calculated at 70 F. It has vbeen found that any greater saturation value than 100 milligrams of plastic per 100 cc. of treating solution is not necessary and limits latitude of teohn'ic in that careful handling is required to .prevent -destruction of the structural form of the yplastic fabrication. vThus in `my tests I have purposely employed treating solutions having saturation values of not over 75 milligrams of 'plastic per 100 cc. of treating solution as I `obtain the desired strength `with the greatest 'latitude 'in technic of application. On the other hand,'I have found that with careful technic the saturation value may be as high as 300 milligrams of plastic per 100 cc. of treating solution and still useful results will be obtained. Also Where the plaistic fabrication has been pretreated, as has been discussed under title Pretreat-ing of the castforming material and will be further discussed in detail in :connection with Figs. 16 rand 1'7, the f'treating solution to be employed `may have a higher saturation value than when non-pretreated material is employed. 'For example, the range fof 50 to 150 milligrams of plastic per 100 cc. .of treating solution at 70 F. is practical for application to pretreated material. .Also .in the .pretreating process the treating solution should have -a lower Saturatie-n lvalue than the saturation 'va-lue of the ksolution vto be employed in the n-al treatment. I have found `for practical purposes the pretreating s- 7'5. Thus where an untreated fabrication was employed, solutions having saturation values of yover 100 require considfer-ably more care in technic than where a treated fabrication vwas 'employed -with solutions having the vsame saturation value. Also, 'in practical casts I thave employed -in the pretreating method, a treating solution having a saturation value of I0 lu-tion should be below iin the treating solution lbetween the plastic inim1`11`igramsf0f plastic per 1-00 cc. of 'treating solulticbeing treated, 'theplastic being'treated is propl'erly treatedsc it will subsequently set-up to provide a practical cast iand Without adverse destrucrtion of the fabrication.

The setting-up action of my cast involves more than `-mere evaporation of an extremely dilute :cement or adhesive. I vhave taken a saturated treating solution'of the vcharacter above discussed and :applied the same to -a material to which the #solution is linert, as cotton, and evapor-ated all liquid. Instead of finding, fas might be expected, some residue eencrusting l'or hardening the cotton, the cotton `appeared-tobe the same as it was before the treatment. :amount fof residue that its presence 4was difficult to "detect by the physical appearance y.or the feel of the cotton. YI-n lcontrast y'thesame treating sovzl-tition when :applied toa plastic fabrication provsides a rigid structure. fof fthe setting-up action ol a cast of my 'inven- -iii'on inclu-des unexpected Vfactors land cannot be explained 'as lbeing merely :the providing of a limited :amount of cement iin solution and then evaporatin-g the liquid.

vIt appears that fthe vminimum `saturation value fof the treatingso'lution-s `or their apparent capacity to dissolve additional `plastic may be Vsub'- :stantially zero .and such Atreating Vsolutions will 'be '.higlilyuse'fu'l in Ilmy invention. As -to the maxfoperation, it was found that .rather low saturation value, the loops in the weave are sufiiciently self-sustaining so that the tendency of the material to run is substantially decreased. This 'feature of my yinvention has great utility in the cast eld `and also has Agreat futility in yother fields such fas in the treatment of Thus the phenomenon o5 iing solution to 'tical purposes, should be '.Womens stockings or hosiery Imade of a soluble There was such a small 60 Plastic.

The mild or light pretreatment does not too ladversely eiect a harshness to the material :and at 'the Vsame time it provides suicient loop .retaining characteristics so that there vresults a practically run-proof product. The mild treatbe thus employed should have a 'saturation value in the `neighborhood vof '10 milligrams per cc. of treating solution at 70 F'. -As the strength of solubility of the treating solution increases it increases the harshness of the .material so that `the treating solution, for practhe lowest treating solu- `tion Which will `provide the rdesired runproof `characteristic.

It :is interesting to `note the very small total he dissolved by the treating solutions of this invention. A considerable excess of treating solution for a given cast was applied and the capacity `of such solution to dissolve the plastic involved was determined. It was found that the weight dissolved was less than one-half of one percent Technic or method of invention, apparatus emplaying method of @retreating cast-forming material Referring particularly to Figs. 16 and 17 of the drawings, a device embodying my method of pre- ;treating the plastic cast-forming material is illustrated. This device employs a treating solution in the pretreating process, but my invention can also employ either heat alone or a treating solu- -tion plus a heat treatment.

. Also, the device as illustrated provides for immersion of the fabrication in the treating solution and my process also includes, spraying, ap-

-plying with a brush or the like, or pouring the treating solution on the fabrication.

The device comprises a frame and housing means 20. A liquid trough means '2| is disposed at the inlet portion of the housing means 20.

lIn order to provide the desired liquid level of treating solution in the trough 2|, I provide a source of supply of treating solution 22, syphon conduit means 23, and float valve means 24--thus a' predetermined liquid level of treating solution l is maintained in the trough means 2|.

A source of material to be treated is carried by driven roll 25. The material 216 to be treated (the nature of which has been hereinbefore discussed in connection with the titles Plastic employed and Form of materials) passes downwardly from the driven roll 25 and is supported by guide plate 21. The guide plate 21 is inclined downwardly and due to the weight of material and the loose stitch of the fabrication, the mate- 1 rial tends to crowd together or reduce its length.

As the fabrication 25 leaves the guide plate 21, it. passes under driven feed roll 28 which is provided with peripherally positioned spikes or pin means 29. The fabrication 26 in passing under and around the driven feed roll 28 passes below the surface of the liquid treating solution in the trough 2| and the spike means 29 tend to maintain the excess material or the shortened length of the fabrication as the same passes around the driven feed roll '28. The fabrication 26 then passes upwardly and over a second driven feed roll 3G which is provided with spike means 3| which are similar in nature to the spike means 29 of the driven roll 28'. Thereafter the material is i delivered from the feed roll 3|! onto a driven endless conveyor belt 32. In a typical installation a treating solution having a saturation value of IB (in accordance with a standard hereinbefore mentioned) was employed and the feed of fabrication was regulated so the fabrication was immersed in the treating solution for about one and one-half seconds. However, with change of saturation value of the solution, change of period of immersion is preferable. The endless conveyor belt 32, the feed rolls 28 and 36, and the trough 2| are all formed of materials which will not be affected by or affect the treating solution. Also the endless conveyor belt 32 is a porous belt such as a perforate wire belt so that air may be passed through said belt and through the fabrication 26 resting on the conveyor belt 32. Material discharging from the endless conveyor belt 32 is supported by a plate 33 and from there is delivered onto an endless conveyor belt 34 in a second housing 35.

The endless conveyor belt 32 is supported on driven rolls 36, and the speed of travel of the endless conveyor belt 32 is slightly less than the peripheral travel of the driven rolls 28 and 30. Thus material leaving the second driven feed roll 30 will be crowded or the length of the fabrication will be shortened. Thus in two instances, namely, between the delivery of material from the roll 3|] to the conveyor 32 and from the delivery of the material from the guide plate 21 to the roll 28 provision is made to crowd, or longitudinally shorten the fabrication 2t. In view of the pretreating action of the solution in the trough 2| provision is made to maintain the fabrication 23 in its shortened length which is obtained from said mechanical means just described and also said solution functions to shrink the fabrication 26.

The housing means 2|) preferably completely encloses the fabrication 26 while the same is being treated except for the inlet and outlet means for the fabrication and an inlet means 31 and an outlet means 38 for the admission and exhaustion of air. In close proximity with the inlet 31 is preferably provided a driven fan 39 which will augment the amount of air passing into and out of the housing 26. The air leaving the fan 39 passes upwardly through the conveyor 32 and through the fabrication 23 disposed on the upper flight of said conveyor 32. After the air has passed through the material on the endless conveyor belt 32 it passes out outlet 33 and up conduit 40. Preferably conduit lli is provided with damper means 4i to adjust the size of the opening of said conduit. Preferably the conduit 40 connects with a conduit d2 in which is disposed a fan 43 which augments the exhaust of gases out said conduit 42.

At the inlet end of the machine preferably is provided a sliding door M which is preferably made of glass to provide both visibility and accessibility to the interior of the housing means 29. 1

The fabrication 26 has first been crowded or shortened longitudinally, and then has been immersed in a treating solution in the trough 2|. Thereafter the feed rolls 28 by reason of their spiked peripheral portion have maintained such shortened longitudinal length and then thereafter the fabrication 26, which has been immersed in the treating solution, is again crowded. onto the conveyor belt 32 and the longitudinal length has again been shortened. Thereafter by a drying operation the wetted pretreated fabrication 26 has been dried and the action of the pretreating solution is to loosely set or maintain the fabrication 26 in its shortened longitudinal length. This portion of the process is a mechanical shortening -of the fabrication 2B. At the same time the treating solution in the trough 2| will have a physicalchemical reaction with the fabrication 2E and upon the drying of the fabrication there is a shrinkage of the fabrication 2t in all directions. Also in the physical-chemical reaction of the 15 treating solution with the fabrication 2E any eX- cess material. which. has been crowded. in the `fabrication 2t willbe maintainedA in the fabrica,-

tibn 2.5i and in fact I have found in actual tests that the thickness of the fabrication 2t may be increased because of the pretreating process. The

fabrication 26 before treatment is diagrammatieally. shown in. Fig. 1 of the drawings and said fabrication. after. treatment is diagrammatically lshownin Fig; 2-'of the drawings. It will be noted that` while the length. of the loops have been shortened, their thickness or dimension at right angles to the length has been increased by the pretreatment process.

In order to maintain the mechanism within reasonable commercial length limitations, preferably .i155

the fabrication 26 leaving or discharging from the conveyor belt 32 is passed through the second .housing Slandf there subjected to heat of a temperature to remove all traces of liquid resulting from-the treating solution. Obviously if the endless: conveyor belt 32 were of sufcient length and suiiicient air were passed through the fabrication izthercon, the material could be completely pretreated? and dried in the housing 23. In view of 'the fact that someA of the preferably employed volatile solvents are inflammable, in the interest offfcaution, a separate housing is illustrated in crderthat heat may be safely applied in the drying process.

Within the housing belt 34 which is similar in structure to the conveyor belt 32 and the same is supported by driven feed rolls 45. Below the conveyor belt 34 and within the housing 35 is disposed a plurality of heater means 45, which may be heated by any .f

suitable source, such as electricity. The heat rislng from the heaters i6 passes through the ccnveyor belt 34 and through the fabrication disposed on the upper night of said conveyor belt.

In order to provide a source of air for thehousing i 35, preferably I provide an adjustable closure means l 9 adjacent an opening in the bottom portion of the housing 351. The warm air rising in the housing 35fpasses out thr-ough conduit 111 which is connected with conduit 42. In view of the fact that I am merely providing a drying action in the housing 35 to remove anyv trace of treating solution, and in view of the fact that the treating solution preferably contains a highly volatile 35 is provided the conveyor solvent and may therefore be somewhat explosive, 5()

the temperature and volume of air withinl said housing 35 should be regulated to prevent ignition of any liquid remaining on the fabrication 26 when the same is within the housing 35.

Toward the discharge end of the conveyor belt 34' is provided an idler roll 43 which functions as 'ahold-down means for fabrication 26 on the con- Veyor belt 34. Fabrication 26 dischargingv from the conveyor belt 34 passes over plate t8 and then is wound on driven roll 50.

In Fig. 16 of the drawings there is shown diagrammatically the driving connections of the various driven rolls before mentioned. In said Fig. 16, 5! represents a prime mover as a motor which is connected with a speed reduction means 52 (diagrammatically shown). The outlet from the speed reduction means 52 is connected with a sprocket 53 by way of a link belt 5A and said sprocket 53' is carried' by one of the driven rolls such as 35. A means of connecting the various driven rolls together comprises a sprocket 55 carried by roll l5 and a link belt 56 between sprockets 53 and 551 The conveyor belts 32 and 34 may be utilized in transmitting rotary movement between the twodriven rolls 36 and-the-two driven 75 r16 rollsrespectively. The drivenl roll 361- atftlie intake end of the machine is provided with a sprocket. 5l which is connected to speed'regula.- tor 5S (diagrammatically shown) by means-cfa. link belt 5t. The speed regulator 58is connected by a link belt it with a sprocket 6l on driven=r0ll 28. A means for interconnecting driven rolls 30 and 28 so the same will rotate in oppositediirections comprises sprocket 62 carried by'. roll 3G: and link belt t3 which interconnects sprockets 6I and e2. Thus the peripheral speed of the rolls28 and 3@ may be adjusted relative tothe peripheral speed of the rolls 36 and in turn of the conveyors 32 and 34. The regulator 58 is ofthe manual adjustable type so that adjustment. for different types of weave or stitches of fabrication is, possible. In order that the lineal feed or dis.- charge of fabrication 26 from the roll 25 shall remain constant irrespective of the size of the roll of fabrication 2t on said roll 25, I provide a, speed regulating means 34 (diagrammatically shown) and connected with sprocket 51 by means of link belt $5. This speed regulating device2 is preferably of an automatic type and is connected by a link belt 66 with a sprocket 61 carried: by. roll 25.

Referring to the discharge end' portion ofthe machine, the driven roll 45 at said end is connected with the take-up roll 5t through a speed regulating device 8f3 (diagrammatically. shown) by. means of link belts 69 and 10 and thus the peripheral speed of fabrication 25 fed onto rol! 5ll=will be the same despite the fact that the size ofI roll formed by the material is increasing` with production.

In view of the fact that material discharging from the roll 25 is being crowded and longitudinally shrunk it is desirable that the roll 25 be driven and that there be no strain or pully on the material as the same is being fed. Also prefs erably similar results are desired in connection with the take-up roll 5t so that after the material has been treated it is not stretched.

As the peripheral speed of the rolls 28 and 3l are the same and such speed is slightly greater' than the peripheral speed of the conveyor 32; there'is a physical crowding of the material4 to gether or shortening of longitudinal length ofthe same when it is deposited on the conveyor 3:21 Ther amount of this physical crowding I have found preferably to be the maximum which a. particular knit or stitch will permit. Thus iff the fa-brication 26 is very loosely knit and' a great crowding is ermissible, then the rolls 28 and 30' will have a substantial increase of speed over thev peripheral speed of the conveyor 32. In some stitches I have found that it is possible to longitudinally shorten, during the pretreating process, twelve longitudinal feet of material into ten longitudinal feet. One test for determining. theV preferable relative peripheral speed of the rolls 28 and 3i? as compared to the conveyors 32l and 3c is to crowd all the material that is posev sible onto the conveyors so long as the material lies iiat and does not buckle.

I have found that a method employing treating solution in pretreating the fabrication without the use of the mechanical crowding is highly useful, and it is to be understood that the use of both the treating solution andl themechanical crowding is a preferable method but not an essential one.

Also, in the device of Fig. 16, I have provided for drying of a fabrication which has been me,- chanically crowded and treated by the treat.-A ing solution. For such drying, the material is sisma 17 preferably supported on an open mesh conveyor` and heated air is passed through the conveyor and the supported material. Y

Referring particularly to Fig. 17 of the drawings, a device embodying my method of pretreating the plastic cast-forming material where heat is employed is illustrated. The materials to be treated in said device may be the same as fabrication 26 discussed in connection with Figs. l, 2, and 16, either before or after treat? ment by the apparatus disclosed in Fig. 16. Obviously, if the fabrication 26 has been treated by the treating solution of the before mentioned Fig. 16, the treatment should be rather light if al subsequent treatment is to be made in the device' f Fig. 17.

Plastic fabrication material 1| is disposed on` feed roll 12 and the same respectively corre-` spond to fabrication 26 and feed roll 25 of Fig. 16. Frame means 13 supports a housing member 14 and also the various other structures. A conveyor 15 is supported by driven roll 16. The conveyor 15 is similar to the conveyors 32 and 34 of the previous Fig. 16. Above the conveyor 15 are mounted pivoted arms 11 (only one of which appears in the elevation-Fig. 17) and the free ends of said arms 11 support a peripherally spiked roll 18, which is preferably an idler roll. The construction of the peripherally spiked roll 18 is similar to that of rolls 28 and 30 of theV previous figure. As one form of spikes, there may be employed standard steel phonograph nee-` dles projecting radially from the roll with their pointed ends about 1 3@ inch from the 'periphery thereof.

Plastic fabrication 1| is fed from feed roll12.

between idler roll 18 and driven conveyor 15 and thence to and over plates 19 and onto conveyor I0 which is disposed within the heat chamber provided by housing 14. The conveyor 80 is supported by driven roll 82 which provides a peripheral speed to the conveyor 80 which is less thanthe peripheral speed of the conveyor 15. Thus Il provide a crowding action of the material and reduce its longitudinal length while the material is being subjected to the heat treatment within the housing 14. The structure in the gure herein discussed is slightly different from the structure in Fig. 16, but in each instance I provide means for crowding the material or reducing. the

jected to treatment while in such condition. In each instance mechanical means of slightly different nature are employed and substantially the. same crowding action results.

It is desired that the plastic fabrication y1|- shall be subjected to a temperature of about 23'15"'` F. for a period of approximately 25 seconds. A

way of providing such temperature is to form'the walls of the housing 14 from heat insulating materials. Openings 83 provide for the inlet of. air, and the air passes downwardly between thewalls of the housing 14 and the inner walls 84. Within the chamber formed by the inner walls passes downwardly outside the walls 84 and upwardly inside the walls 84 and pastl the heaters 85. Airrising past heaters 85 passes through the perforate metallic conveyor 80 and through material 1| disposed on said conveyor. Then theheat- 7 passes out of the heating chamber via conduit 8.6 I, which is preferably provided with a fan 81 therein:`

to aid in circulation. In heat treating the material moisture, oils commercially used insurface coating, and plasticizer from the acetate. are

18 s gasied, and therefore preferably I desire notto recirculate the gases but to exhaust the same via conduit 86.

Material leaving the heating chamberformed 5' within housing 14 passes over plate 88 and. onto a conveyor 89. The conveyor 89 is supported by driven rolls 90 and the conveyor 89 has the same travel as .f conveyor 80. Above the conveyor 39 are disposed l0 pivoted arms 9| and 93, and the free ends of the pivoted arms 9| and 93 respectively supporty peripherally spiked rolls 92 and 94, which are preferably idler rolls. Material received on conf; veyor 89 passes thereon and below spiked idler,v f5 rolls 92 and 94 and then is Wound on driven take-fI up roll 95. sponds to the roll 50 'of the previous Fig. 16.

In said Fig. 17 of the drawings there is shownj diagrammatically the driving connection of the 20" various driven rolls. 96 represents a prime mover as a motor which is connected with a speed reduc-- TheI rotary movement between the two driven rolls- 82, and the two driven rolls 90 respectively. The driven roll 82 at the intake end of the machine2 is provided with a sprocket |03 which is con' regulator 58 of Fig. 16) by means of a link belt |05. The speed regulator |04 is connected by a link belt |06 with a sprocket |01 on a driven roll veyor 15 so the same are both driven.

By manual control of the speed regulating` means |04 (similar to speed regulating means 58 of the previous Fig. 16), variations in the rate of ,speed between conveyors 15 and 80 may be pro-' vided so that conveyor 15 will crowd excess mate-fl rial onto conveyor 80 and to the extent described in connection with Fig. 16.

A link belt |08v interconnects driven sprocketA |03 with a speed reduction device |09 which is V; similar to the s eed reduction device 64. length of the material so the same may be subv p The speed reduction device |09 interconnects with a sprocket carried by roll 12 through 'link beltV 10. Thus the rate of feed of fabrication 1| from ;=r supply roll 12 may be regulated by speed regula- V tor |09 similar to the action described in connec-y tion with the regulation of feed from the feed` roll 25 of Fig. 16.

Both rolls 90 are driven as they are intercom nected by conveyor 89- The driven roll 90 at theyV discharge end of the machine is connected to' fabrication take-up roll 95 via link belt l2, speed g The4 parts |l2, H3, and H4 correspond respectively to` .3L-@the parts 69, 68, and 10 of Fig. 16 and have, simi-'l 84, electric heaters are disposed and the airl 6 i reduction device ||3, and link belt ||4.

5 lar functions.

The range of temperature to be employed within fof pretreatment of the fabrication and the 0 amount of shrinkage desired. Also it mayY be: that the fabrication has been pretreated inV -the machine of Fig. 16 withra treating solution so that the treating t0 be accomplished in the' maehinej of Fig. 17 will be relatively light. Also, it may t 75 be that it is not desired to remove all of the This driven take-up roll corre- 99 and said sprocket 98 is carried by one of the.

The conveyor." belts 86 and 89 may be utilized in transmitting' nected to a speed regulator |04 (similar to speed'y 16. The driven rolls 16 are interconnected by con-1* butted.

-19 shrink from the materia-l4 and for such reason a lighter 'treatment'vmayfbe desired. For practical purposes I -have'vdetermined that the range of temperature in the heat treating chamber ill'may beflbetween 350 F. and 425 Rand thatthe material willbe in said device and 'exposed yitc-said heat (by being contacted with a heated fluid-a gas for a iiliid--heatedIair bei-ng shown by `way ofexample) vfor `a period of '30 to 10` seconds.

Furthermore, inconsidering the amount of pretreatment to be employed it is highly desirable to reduce 'the-same to a minimum as the greater the pretreatment'the'hars'her or vmore "set islthe material. "It appears'that evenif the pertreatment is'rather'light, still, all detrimental shrink` age may v'be removedandattire-'same 'timethe material -can be ymaintained rather lsoft and smooth feeling to the touch and therefore has highly desirable qualities 'as a prepared plastic cast-formingfmaterial. j V"Ih-us in the'pretreatment'process, a vliquid treatmenhaheat treatment',VV or a combination of thertwo may'beiemployed'but preferably a liquid treatment in-Wlfrole n'or in part-is 'employed -as va more :uniform treatment, cross sectionally 'con-- sidered fof the piasticfseems to'result.

Application `of -plastic fabric fIn the :event thatthe invention is employed in providing a .cast or splint,` preferably the'skin areatube:contactedbyfthe castshall be covered withf amaterial iinertto the treating solution, such as.stockinettepsheet-wadding, felt orrayon bandage. inthe-events that itfis desired to apply' the cast .directlyadjacent the'skin of a patient, the comfcrtof thegpatientwillbeenhanced by shavingpii' any hair-and :applying'a-greasing coating as a -viscous-mineralxoil.

7Over the vskin or over fthe' padding layer, the plastie'material in-:strip or:bandage ."form isf wrapped. In many cases :it mayebe'desired to wrap .more than :one'layer from fthe strips `being employed -andinmanycasesitzmay be desiredto wrap -oneflayerwwith the A'joints ,lapping at Aapproximately-the center :of the bandagezand then to.. apply ya second ylayer where the :joints between adjacent :edges are butted-.or a Isecond layer in the form of a tubular member.. .In the event that the cast-iste beformedof twor-laylers it is preferable toiapply the first plastic.layerwettedwith treat-a: ingfsolution rand vthe second plastic layer dry.'

.Howeven either-layer-may begapplied wet or dry.

I :have `found very :desir tained if theirstlayer c able results may be obomprises a plastic fabri-v cation pretreated in `accordance .with the1b`efore5 111enl'ionedrnethod-.and'thenfafterv saidlayer has substantially set, to y appl of non-pretreated material-for appearance this may -fbe va tubular .membertof-thus provide` a continuous .exposedsurface By applying an cuterf-fV non-pretreated -layernit tendsito shrink onto the" first-layer and uniiyithe cast land :at the same time the underl'layer or Vpretreated.material will not .shrink .upon settingbecause zof the pretreatving-.methodand thusI 'have awell conforming and...l

unified cast.

.Referring to Figs. 6 and V'7 :of r the drawings, il' |26 indicates the `inert padding material, v| I7 `indicates .the :first .layer whereinv adjacent portions cates' ther outer-.layer wherein :the `joints are preferably :Referring to. Figs-- 8. and -9 :fof the drawings, |.|6 again-:represents .liner-t padding material, l'l again indicates the .first layer and |32 :represents/.the 'y voir] 23 fortreating .reservoir -|23 communicates with the chamber* A screw vcap V|25 is provided. g means and also asa .means 1 The ysize :of theport f vllwissuch'that thetreating solutioninthe res; into the chamber and .at the y same .time 'f amber l 28 will .be upl to v; |24. A tray-like member |3| astio fabrication;

mesma 20 outsidestockinette or one'piece. v In applying the 'treating solution tothe plastic fabrication, the` fabrication may be-Wetted `with treatingsolution'beforeit .is applied or elsethe :plastic .fabrication ;may be applied andthen the same wetted. Inprder to apply the treatingsollutiontothe:plastic fabrication, theplastic fabrication may' be immersed in treating solution or the treating solution may be .poured .on,

f. applied "by a 'syringe .or spray gun, -or applied vJing solution. Als

tical v'methodis Yprovide 'therein a Amember .|21 has itsend the'two piecesfonningthe cover marine slidingly moved.

'xneans'ii28 is hingedlysupportedon -the cover; |29 andra spring;

30e-trieV rod |22 -is moved upwardly i-t-,is only necns `|2| downwardly:A |22 is V,positionecLin :its desired vupperposition it will beheld in such upperfposi-f- |28. Areser-l;

and;a'fter the rod to function as y'fa :second Aplastic `layer same time, in view of the preferableI tureof the'treating solution infthec fumescf'said treating solution will :isprovi'ded onwhich a roll of pl rmeansbll is opened and the tray y rlcation IIZE'thereon is. lowered into the chamber# f vthe treating,so,. er the plastic fab,- rication |26 has been lthoroughly ywetted .thenbyjfa brush to .wetfthe V'plastic fabrication. ,A very'jpractical way of 4.applying treating .sointionto `a plastic' fabrication, however, :is :byza syringe emitting a smallstreamor spray of treat. o`, f'the plastic fabrication is to, be immersed in thetreating solution a very pracby the'. deviceshown in Figpl4-'of the-drawings. )In 'said Fig. 14, H9 represents a container .to chamber V|210. A split cover;

means (|21 to .the container 1| I9. Intermediate member |2| isv provided an ,opening throughwhicha rod `|22 v Preferably -a catchmeni'ber v12| by pivot means means 13|? angularly .moves th into engaging relation Vwith a e catch-means |28 rod |22. Thus if essary vto hold 'the .cover mea tion `by reason of the catch means solution isprovided and said |29 via port |24.

a fillin to 'seal 'the reservoir |23.

ervoir A'|f23 will bedelivered in a 'rather small stream thediquidlevel in the ch the level of the port |26 maybe disposed.

In the operation ofthe.

|20 and below the liquid level o .lutioninisaidchamber |20.. .Aft

oved. upwardly and .by reasonof thev catchtmeans yin Aan `operating room vthedfabrication .maintained in a closed container.

that'aV wetted 'fabrication may .be 4a `wetted'condition andin the abs supply readily available for him.

7 5 .A bodying-the structure `of saidFig. '14 proves izo-be.;

tubular layer formed v`bf vportions.hinged by hinge device shown in Fig. 14, va-roll df v,plastic fabricationis:disposed aboutthey vThen the cover-1; |3| with the'fab- |28 itisretained at a-levelabove the liquid solntioninjthe chamber |20. Thus |26 will-.bee- Also Vat the volatile na-v v hamber |2|i,'.-A .bepresent so. maintainedin f' ence .of drying "conditions so that 4it will be readily Vavailabieso that as the physician needs further wetted `fabv'rication in 'applying .a cast there vwill .also be a 'g very practical. It can be readily understood that it requires a mere movement of the rod |22 upwardly to remove the fabrication |26 from the treating solution and at the same time when the fabrication is rst placed on the tray |3| that as the cover means close, the fabrication may be at once immersed in the solution in the chamber Y |20 or the fabrication may be maintained at a level above the solution by reason of the catch means |28 and thereafter immersed as and when desired by the physician.

When a plastic fabrication is immersed in a treating solution of my invention, I have found that some of the treating solutions tend to be selectively exhausted as to one or more of the components of the treating solution and therefore it is desired to periodically replace the treating solution into which the fabrication is to be immersed so that the saturation value of the treating solution may be maintained within the desired range.

In the event that the liquid draining from an immersed fabrication is not permitted to deposit inthe treating solution, then of course it will not be`v desirable to periodically replace the treating solution.

In the event that a cast is to be applied over surfaces, such as bony prominence or sore spots, it may be desired to provide a padding at such locations and this may be readily accomplished in my invention. Referring to Fig. a padding material |33 such as cellulose acetate staple, or sheet wadding, or soft glass wool `is disposed adjacent the local area and the cast material formed thereover so that the desired padding structure is present. In the event that the padding material employed is a cellulose acetate staple, the outer portions will be adhered to the cast and the inner portions will remain untreated in view of the resistance to wetting or being penetrated by a liquid of the cellulose acetate staple. In said Fig. A10 the balance of the cast may follow the structures of either Figs. 6 and 7 or Figs. 8 and 9.

In the event that it is desired to provide eXpan sion joints or local areas in the cast which are not to be set-up, this may be accomplished by employing a material which will not be affected by the treating solution, will not be Washed 01T or dissolved by the treating solution, and one which will Ienvelop or encase a portion of the fabrication so that such fabrication in such area cannotbe affected by the treating solution. As an example of such a substance which may be employed with the fabrication and the treating solution of this invention a thin jelly-like solution of gelatin and water may be employed. Furtheri more such jelly material may be washed or brushed out after the cast has been set-up and then upon removal of the jelly, the portion of the cast'which was protected by the jelly may be subjected to a treating solution and such portions then set-up.

Referring particularly to Figs. 8 and 9, |34 represents areas which have been protected so that the same have not set-up and may provide expansion joints. The method to be employed in providing non-set-up portions of a cast is more fully disclosed in my copending application Serial No. 469,843, the difference in the present instance being in the nature of thefabrication,

thetreating solution, and the coating material.`v

Another feature of my invention relates to the cutting of a cast so that the cast may be removed, repaired, or adjusted. In the prior art of plaster of Paris casts, the task of severing the cast in 22 `1 many cases, as a body cast, was such a strenuous and tedious task that it has been termed a hammer and chisel job. As distinguished therefrom, in my cast the same may be chemically or mechanically severed or a combination of the .i two may be utilized and at the same time with a I minimum of effort. Preferably an inert absorbent material, as sheet wadding, is applied over the l area (local or for the length of the cast) on which the cut is to be made. Then acetone is sprayed or applied to the sheet wadding. The sheet wadding functions to provide acetone in the desired area or region and at the same time the acetone can function as a dissolving agent of the cast. 'Y

`The cast which has been so treated has been found to be readily severable so that it is only necessary to use ordinary bandage shears and the cast may be severed or local areas removed as may be desired. Thus I have been able to supplant the old process which was involved in plaster of Paris casts and which was a hammer and chisel task to a procedure wherein the cast may be severed by mere bandage shears. Even if the acetone is not applied to provide the dissolving* action above described, it has been found that the cast may be severed withgreater ease and with less difficulty than was required with the old plaster of Paris cast.

Referring to Fig. l1 of the drawings a completed cast |35 is illustrated as having disposed thereon sheet wadding |36. Thereafter the sheet wadding |36 is wetted with acetone and a desired local-areaof the cast |35 is so dissolved or softened that it may be readily removed or reshaped. Preferably the material will merely be reshaped, as an opening may cause window edema. However, if an opening is provided, then as shown in Fig. `12 of the drawings, the material |31, which may be similar to material |36 of Fig. 11, is preff erably disposed in the opening provided in the cast |35, and cast-forming material |38 may be Hf applied and the same may be adhered to and form 'i an integral part of the cast |35. Thus, in the event of sore spots developing under a cast, portions of the desired shape of the cast may be i application of further treating solution, the patch or repair material will be firmly adhered to the cast and the cast will have its original strength. In the past where plaster of Paris casts were employed, the strength of the cast depended upon the maintaining of its original structural form and any repair caused a weakening of the cast unless the repair work in substance involved the making of a new cast.

Referring to Fig. 13 of the drawings a fragment of a cast |39 is illustrated and padding |40 similar to padding |36 of Fig. 11 is shown. Thus in the eventthat it is desired to provide slits in a cast to remove the cast or to adjust the cast for sise, it is only necessary to provide the mate- -rial |40 to form a strip and then acetone may be applied to the material |40 to dissolve the cast. Thereafter by bandage shears the cast may be severed for removal or adjustment. If the cast 3 is severed for adjustment then a strip of bandage material may be applied similarly to the descrip- 23 tion :in connection with Fig. v12, and the cast repaired after Athe adjustment has been made.

"This invention accomplishes the various objects which were set forth in the first part hereof and provides further results which have been set forth in the description 4of the various structures and methods. It is believed the same are therefore :sumcient without further setting forth the same at this place.

Obviously, changes may be made inthe forms, dimensions, and arrangements of the parts of my invention, without departing from the principles thereof, the above setting forth only preferred forms of embodiment.

l-l. In the process of .making an orthopedic brace, the step which comprises thoroughly wetting a fabric formed of plastic fibers which is soluble in a volatile organic setting agent, the setting agent being characterized by having a saturation value for the plastic of between 50 milligrams and 300 milligrams per 100 cubic cen- 1 timeters of setting agent at 70 F., whereby upon allowing the solvent to evaporate there is formed a brace of ysubstantially unyielding and inelastic construction.

2. In the process of making an orthopedic brace, the step which comprises -thoroughly wetting an open mesh fabric formeel of plastic fibers which is soluble in a volatile organic setting agent and which :open -mesh fabric incorporates therein pieces `of reinforcing material insoluble in said setting agent and which reinforcing material functions to aid in maintaining the form of the fabric when wetted, the setting agent being characterized by having a saturation value for the plastic of between 50 milligrams and 300 milligrams per 100 cubic centimeters of setting agent at 70 F., whereby upon allowing the solvent to evaporate there is formed 'a brace of substantially unyielding and inelastic construction.

3. In .the process of making an orthopedic brace, the steps which comprise pre-shrinking a a :fabric formed of plastic fibers which is soluble in a volatile organic setting agent; and subsequently, for application `as la brace, thoroughly wetting such fabric by a volatile organic setting agent in which the same is soluble, the settting agent being characterized by having a saturation value for the plastic of between 50 milligrams and 300 milligrams per 100 cubic centimeters of setting agent at 70 F., whereby upon lallowing the .solvent to evaporate vthere is formed a brace of substantially unyielding and inelastic construction. y

4. In the process of making an orthopedic brace, the steps which comprise pre-shrinking afabric formed of plastic fibers which is soluble in a volatile organic setting agent by employment of such a vsetting agent having a saturaton value of less than 75 milligrams per 100 cubic centimeters of solvent at 70 F.; and subsequently, for application as a brace, thoroughly wetting such fabric by a volatile organic setting 'agent in which the same is soluble, the setting agent being characterized Vby having a predetermined saturation limit for said plastic to gelatinize and dissolve part thereof without destroying 'the structure of .the fabric, whereby upon allowing the solvent to evaporate there -is formed a brace of substantially u-nyield-ing and inelastic construction.

T5. In the process of making an orthopedic.

brace, the steps which comprise pre-shrinking a fabric formed of plastic bers which is soluble in a volatile organic setting agent by employment of heated fluid at a temperature of' between 350 F. and 425 F.; and subsequently, for application as a brace, thoroughly wetting such fabric by a volatile organic setting agent in which fthe same is soluble, the setting agent being characterized by having a predetermined saturation limit for said plastic to gelatinize and dissolve part thereof without destroying the structure of the fabric, whereby upon allowing the solvent to evaporate there is formed a brace of su'bstantially unyielding and inelastic construction.

6. In the process of making an orthorpedic brace, the step which comprises thoroughly wetting a fabric formed of plastic i'lbers which is soluble in a volatile setting agent, the setting .agent being characterized by having a satura.-

tion value for the plastic of between 50 milligrams and 150 milligrams per 100 cubic centimeters of setting agent at F., whereby upon allowing the solvent to evaporate there is formed la brace of substantially unyielding and inelastic construction.

7. In the process of making an orthopedic brace, the step which comprises thoroughly wetting a fabric formed of cellulose acetate fibers `which is. soluble in a setting agent including therein acetone and a diluent which is a Vn'onsolvent for cellulose acetate, the setting agent REFERENCES CITED The following references are of record lin :the`

le of this patent:

UNITED STATES PATENTS Number Name A Date 1,279,106 I-Iall Sept. 17, `1918 1,686,149 Ellis Oct. 2, 1928 1,719,173 Dreyfus July 2, 1929 1,786,421 Buhlman Dec. 30, 1930 1,828,397 Dreyfus Oct. 20, 1931 1,884,589 Davies Oct. 25, 19.32 1,935,263 Ellis Nov. 14, 1933 2,006,540 Dreyfus et al July 2, 1935 '2,060,113 Platt Nov. 10, .1936 2,103,511 Brown Dec. 28, 193.7 2,144,591 Bux et al Jan. 17, 1939 2,156,491 Daniels May 2, 1939 2,158,110 Dreyfus et al May 16, 1939 v2,187,358 Mellor Jan. 16, 1940 2,191,534 Mann et al Feb. 27, 1940 2,218,844 Lovell Oct. 22, 1940 2,252,999 Wallach Aug. 19, 1941 2,271,198 Lyem Jan. 27, 1942 `2,277,049 Reed Mar. 24, 1942 2,282,274 Weiswasser May 5, 1942 2,296,379 Croft Sept. 22, 1942 2,308,511 Hilliard Jan, 19, 1943 2,308,593 Brew Jan. 19, 1943 2,315,002 Lyem Mar. 30, 1943 "2,319,834 Wallach May 25, 1943 2,390,919 Caron Dec. l1, 1945 

